Stucco Composite Building Panel

ABSTRACT

A Stucco Composite Building Panel is disclosed, in which a sheet of exterior wall sheathing and a cement board are attached together to form an improved sheet of building material for the construction of exterior stucco walls. This composite building panel reduces the amount of individual layers required to build a conventional stucco wall by providing an exterior wall building panel that is mounted directly to the stud framing that is ready for a finish layer of stucco to be applied.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefits of the earlier filing dates of U.S. Provisional Application No. 61/814,023 filed Apr. 19, 2013. The disclosure U.S. Provisional Application 61/814,023 is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Completing a conventional stucco exterior surface of commercial and residential buildings is a time and cost intensive process. After the frame of the house is complete, several layers of materials are applied to the exterior frame of the house. Depending on the method, these layers include oriented strand board, foam insulation, stucco, a vapor barrier, a water resistant barrier, and other materials. Each layer adds to the cost of the building project not only due to the cost of materials, but also due to the cost of labor involved with applying multiple layers. Some methods of applying exterior stucco can take as long as three weeks, and if cracks develop, then additional repair is required, costing valuable resources.

In one typical process, a layer of black felt paper or spunbond olefin fiber such as Tyvek moisture barrier is applied to the exterior frame of the building. A sheet of foam insulation is then applied on top of the barrier attached to the framing. Wire mesh is then wrapped around the outside of the foam. After this, an initial layer of Portland cement (stucco) is applied to the wire mesh by hand and a brush is used to rough the surface in order to help the next layer of stucco bond to the surface. Once the stucco is applied to the exterior, it has to cure, which can take as long as two weeks. Once it cures, cracks can form in the stucco, which have to be patched, taking additional time and resources. Despite the intensive process of applying it, stucco appeals to builders and homeowners due to its appearance and versatility. However, this process poses many challenges to home builders, for example:

-   -   1. The conventional multi-layer stucco process is time intensive         and can take up to 20 days or longer to complete;     -   2. Each layer in the process has to be individually applied to         the exterior, which consumes excessive labor and increases the         risks of an incorrect application;     -   3. The multi-layer process produces waist and excessive clean         up;     -   4. Water damage and mold growth over time can occur due to         improper applications of multiple layers.     -   5. It is difficult to control the precise thickness of Stucco         layers being applied by hand resulting in varied finished wall         thicknesses that can lead to future problems such as cracking         and water damage.

Thus there is a need for a stucco wall system that eliminates the process of applying multiple layers and is light, protective, and cost efficient.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a composite exterior stucco wall system with shear strength that is ready to accept a finish coat of stucco by coupling with adhesive a thin layer of cementitious board such as Hardie Backer or Durock with an exterior sheathing such as oriented strand board, plywood or an exterior gypsum board such as DensGlass Gold.

In another aspect of the invention, the adhesive that bonds the cement board to the substrate contains a water resistant element to protect the wood substrate from moisture.

In another aspect of the invention, a sheet of black builders paper or spunbond olefin fiber such as Tyvek is placed in between the composite board and substrate to protect the wood substrate from moisture.

In another aspect of the invention the composite building panel is mounted to the wall frame with conventional fasteners such as screws, nails or staples. The wood substrate layer prevents the fasteners from pulling through and compromising the finished stucco wall.

In another aspect of the invention, the combination of a thinner layer of fiber cement board laminated together with the substrate makes cement board easier to cut with a skill saw, jigsaw, or other cutting means without the cement board crumbling.

In another aspect of the invention, the corner edges and butt joints of the substrate are treated to seal against water damage and other elements, either by elastomeric caulk or a similar sealing material.

In another aspect of the invention, the joints are covered with elastomeric joint tape or mesh tape and a layer of water resistant mortar over mesh tape to avoid cracking and to seal the joints to protect the wood substrate portion of the composite board.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:

FIG. 1 is a top down view of the composite board layers which consist of cement board, black building paper, and a layer of OSB (oriented strand board) sheathing laminated together into one sheet;

FIG. 2 is a top down view of the composite board layers which consist of cement board, a layer of water resistant coating and the OSB sheathing;

FIG. 3 is a side angle view of another sheet of composite board being placed adjacent to the second board and directly above the first board creating a joint;

FIG. 4 is a side angle view of a sealant being applied to the edges of the boards to seal them against water and other elements; and

FIG. 5 is a side view of mesh tape applied to the adjacent joining edges of the boards with a water resistant finishing layer being applied over the mesh tape and the adjacent edges of the boards.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 1, a composite board 10 is composed of a substrate 11 that is an oriented strand board or a similar substance such as plywood. A sheet of cementitious board 12 is affixed to the substrate 11 creating a barrier that seals and protects the interior wall. In this figure, a sheet of black builders paper 13 is placed between the cement board 12 and the substrate 11 as the vapor barrier or water resistant barrier. The builders paper 13 is glued to the substrate 11, and then the other side of the builders paper is glued to the cement board 12 such that the builders paper 13 is between the substrate 11 and the cement board 12. In other embodiments, a fiber cement board is attached to the substrate. The composite board consists of a uniform ¼″ thick sheet of cement board laminated to a 7/16″ sheet of oriented strand board of plywood. In other embodiments, a sheet of spunbond olefin fiber such as Tyvek is placed in between the composite board and substrate to protect the wood substrate from moisture. A layer of water resistant coating can be applied to the sheathing to protect the wall from moisture. In other embodiments, the cementitious board is a sheet of cement board such as Durock, a sheet of fiberglass gypsum sheathing such as DensGlass Gold, or a fiber cement board such as Hardie Backer. In other embodiments, the substrate consists of a sheet of plywood, a sheet of polymer, or a sheet of fiberglass gypsum.

In FIG. 2, a composite board 14 is composed of a substrate 15 that is an oriented strand board or a similar substance such as wood. A sheet of cement board 16 is affixed to the substrate 15 creating a barrier that seals and protects the property. In this figure, a layer of glue 17 is placed between the cement board 16 and the substrate 15. This glue has a water resistant barrier element mixed in such as a water resistant acrylic so that the glue itself serves as the vapor barrier for the exterior wall system and protects the wooden substrate from moisture.

FIG. 3 shows three composite boards 18, 19, and 20 fixed to the exterior frame of a building. Composite board 19 is placed adjacent to the sheet 20 and above the bottom board 18, creating a set of joints. A composite board can be attached to the wooden frames by both glue and screws, glue or screws, or other methods such as nails or staples. The substrate in the composite boards provides a backing for a screw, which prevents the cement board from cracking. The combination of a thinner layer of cement board or fiber cement board laminated together with the substrate makes the composite board easier to cut with a skill saw, jigsaw, or other cutting means without the cement board crumbling.

FIG. 4 shows the joint of composite board sheets 19 and 20 being sealed with a sealant such as elastomeric caulk or a similar sealing material 21 such as a water resistant mortar to prevent water damage or other elements from damaging the substrate.

FIG. 5 shows mesh tape 22 applied to the adjacent joining edges where composite board sheets 19 and 20 meet to avoid cracking and to seal the joints to protect the wood substrate of the composite board. In other embodiments, the joints are sealed with elastomeric joint tape. A water resistant finishing layer 23 is applied over the mesh tape covered joints to seal the edges of the composite boards 19 and 20. This coating further protects and seals the exterior wall system. 

Having described the invention, the following is claimed:
 1. A composite building panel comprising: a sheet of exterior wall sheathing and a layer of cementitious board, wherein the cement board is laminated to one side of the sheathing forming a stucco wall building material sheet with shear strength that is ready to receive a finish layer of stucco replacing the base coat of conventional stucco methods.
 2. The composite building panel of claim 1, wherein a water resistant coating is applied to the sheathing to protect the wall from moisture.
 3. The composite building panel of claim 1, wherein, the adhesive that bonds the cement board to the sheathing contains a water resistant acrylic.
 4. The composite building panel of claim 1, wherein a sheet of black builders paper is laminated in between the cement board and the sheathing to function as a water resistant barrier.
 5. The composite building panel of claim 1, wherein a sheet of black builders paper is laminated to the back of the sheathing to function as a water resistant barrier.
 6. The composite building panel of claim 1, wherein a sheet of spunbond olefin fiber such as Tyvek is laminated in between the cement board and the sheathing to function as a water resistant barrier.
 7. The composite building panel of claim 1, wherein a sheet of spunbond olefin fiber such as Tyvek is laminated to the back of the sheathing to function as a water resistant barrier.
 8. The composite building panel of claim 1, wherein, the method of installation includes a moisture resistant sealant applied to the butt joint edges preventing water damage or other elements from damaging the wall.
 9. The composite building panel of claim 1, wherein, the method of installation includes a water resistant mortar applied over mesh tape to seal the joining edges, preventing cracking and creating a sealed exterior wall ready for a final finish coat of stucco.
 10. The composite building sheet of claim 1, wherein, the method of installation includes filling the seams and joints in with elastomeric joint tape and joint sealer after it is mounted, to prevent moisture penetration and cracking at the joints.
 11. The composite building panel of claim 1, wherein, the method of installation includes fasteners such as screws, nails or staples with the sheathing portion of the composite panel preventing fasteners from pulling through.
 12. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board such as Durock laminated to a sheet of sheathing.
 13. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board such as Hardie Backer laminated to a sheet of sheathing.
 14. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of plywood sheathing.
 15. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of fiberglass gypsum sheathing such as DensGlass Gold.
 16. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of sheathing material manufactured from polymer.
 17. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of oriented strand board sheathing.
 18. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board such as Hardie Backer laminated to a sheet of plywood sheathing.
 19. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board laminated to a sheet of fiberglass gypsum sheathing such as DensGlass Gold.
 20. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board laminated to a sheet of sheathing material manufactured from polymer.
 21. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board laminated to a sheet of sheathing material manufactured from fiberglass.
 22. The composite building panel of claim 1, wherein, the layer of fiber cement board laminated together with the substrate makes cement board easier to cut with a skill saw, jigsaw, or other cutting means without the cement board crumbling. 